Our client was a fertilizer company manufacturing urea, ammonium nitrate, calcium ammonium nitrate, and NPK. Both the Computerised Maintenance Management System (CMMS) and maintenance work processes used at the facility were area and unit-based vs. a fertilizer complex-wide, common platform. Maintenance overtime was high, and the productivity of company and contractor maintenance forces was low compared to industry standards. Based on industry norms, equipment reliability was also low and was seen as the major profitability issue.
